Mailer and method of forming mailers

ABSTRACT

A mailer is formed from a blank in the form of a single sheet of material having opposite sides each printed with variable imaging. The blank includes opposite and spaced apart edges. A first fold line extends transversely between the edges of the blank defining adjacent first and second panels. A second fold line extends transversely between the edges of the blank defining a third panel adjacent the second panel. Each panel has ends corresponding to the edges of the blank. Inwardly foldable flaps are formed along the ends of the second panel. The third panel is folded about the second fold line and adhesively secured to the inwardly folded flaps so as to define a first pocket having an open end. Frangible portions are formed along the ends of each first and third panel and adhesively secured to each other to define a second pocket having an open end.

RELATED APPLICATION

This application claims priority of U.S. Provisional Patent Application Ser. No. 60/501,268 filed Sep. 9, 2003, which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a mailer for sending items through the postal system. More specifically, the invention relates to a two-way mailer having an outgoing envelope and a return envelope separable therefrom.

2. Description of the Related Art

Much of routine business and institutional correspondence requires a return response from the recipient. In order to facilitate such a return it is known to forward mailers with a return envelope inside another envelope. However, such mailers are expensive to produce and the postage is costly.

Accordingly, mailers have been developed which are folded to present an address portion on the outside of the mailer and a message portion is provided on the inner surfaces of the mailer. A return postcard is formed on a portion of the folded mailer. Perforation lines are formed in the paper to permit removal of the postcard from the mailer for return by the recipient. However, such mailers lack the look and confidentiality of an envelope and are limited in size.

Accordingly, it is desirable to provide an inexpensive mailer and method of making the same wherein the mailer includes a message portion and a return envelope which are easily formed and easily used.

SUMMARY OF THE INVENTION

According to one aspect of the invention a blank for forming a mailer is provided. The blank includes opposite and spaced apart edges. A first fold line extends transversely between the edges of the blank defining adjacent first and second panels. A second fold line extends transversely between the edges of the blank defining a third panel adjacent the second panel. Each panel has ends corresponding to the edges of the blank. Inwardly foldable flaps are formed along the ends of the second panel. The third panel is folded about the second fold line and adhesively secured to the inwardly folded flaps so as to define a first pocket having an open end. Frangible portions are formed along the ends of each first and third panel and adhesively secured to each other to define a second pocket having an open end.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

FIG. 1A is a perspective view of a first side of an outgoing mailer as according to the invention;

FIG. 1B is a perspective view of the opposing side of FIG. 1A of the outgoing mailer;

FIG. 2A is a perspective view of a first side of an outgoing mailer with the panels folded out;

FIG. 2B is a perspective view of the opposing side of FIG. 2B of the outgoing mailer with the panels folded out;

FIG. 3A is a perspective view of a first side of an alternative embodiment of an outgoing mailer;

FIG. 3B is a perspective view of an opposing side of the outgoing mailer of FIG. 3A;

FIG. 4A is a perspective view of a first side of the outgoing mailer of FIG. 3A with the panels folded out;

FIG. 4B is a perspective view of the opposing side of the outgoing mailer of FIG. 3A with the panels folded out;

FIG. 5 illustrates an apparatus that facilitates a method of making the mailers as according to the invention; and

FIG. 6 illustrates a tool for folding inwardly foldable flaps of the outgoing mailer.

DESCRIPTION OF THE INVENTION

A two-way mailer is formed of a single sheet or blank of printable stock, preferably paper. The two-way mailer forms both an outgoing envelope and a return envelope. The envelopes are formed of panels which are folded and adhered together and include perforated separation lines to facilitate separation of the outgoing and return envelopes, as needed.

Referring to FIGS. 1 and 2, a first embodiment of the two-way mailer is generally indicated at 10. The mailer 10 is formed from a blank having opposite and spaced apart edges 12, 14. A first fold line 16 extends transversely between the edges 12, 14 of the blank defining adjacent first 18 and second 20 panels. A second fold line 22 extends transversely between the edges 12, 14 of the blank defining a third panel 24 adjacent the second panel 20. Each first 18, second 20 and third 24 panel has ends corresponding to the edges 12, 14 of the blank. Inwardly foldable panels 30 are defined along the ends of the second panel 20. An apparatus for folding the inwardly foldable panels 30 over the second panel 20 is described later in greater detail.

A first pocket is formed by folding the third panel 24 about the second fold line 22 and adhesively securing the third panel 24 to the inwardly foldable flaps 30. The first pocket includes an open end, through which items, such as coupons or letters, can be inserted into the first pocket. It should be appreciated that any suitable permanent adhesive can be used for securing the inwardly foldable flaps 30 to the third panel 24.

Frangible portions 32, 34 are defined at the ends of each first 18 and third 24 panel. More specifically, a line of perforations 36, 38 is formed along each end of each first 18 and third 24 panel to facilitate separation of the frangible portions 32, 34 therefrom. A second pocket 40 having an open end 40 a is formed by first folding the first panel 18 over the second panel 20, then adhesively securing the frangible portions 32, 34 of the panels 18, 24 together. Any suitable adhesive, preferably a permanent type of adhesive, is used to couple the frangible portions 32, 34.

A third fold line 42 is formed in the second panel 20 to define a first flap 44 that can be closed over the open end of the first pocket. That is, the first flap 44 extends between the second fold line 22 and third fold line 42. An adhesive is disposed along the first flap 44. The adhesive allows the first flap 44 to be secured to the third panel 24, thereby closing the open end of the first pocket. Alternatively, the first flap 44 can be defined in the third panel 24 and secured to the second panel 20 to close the open end of the first pocket.

Inwardly foldable flaps 30 are defined at the ends of the second panel 20. Preferably, transversely extending cuts 31, 33 extend inwardly from the edges 12, 14 at each end of the second panel 20. The cuts 31, 33 facilitate folding of the flaps 30 relative to the second panel 20. Most preferably, one of the cuts 31 at each end is aligned with the second fold line 22, while the other of the cuts 33 is spaced apart from the first fold line 42.

A fourth fold line 46 is formed in the first panel 16 defining a second flap 48 that can be closed over the open end 40 a of the second pocket 40. An adhesive is disposed along the second flap 48. The adhesive allows the second flap 48 to be secured to the second panel 20, thereby closing the open end 40 a of the second pocket 40. It should be appreciated that any suitable adhesive known to one skilled in the art can be used for securing the flaps to the panels, such as a re-moistenable gum adhesive or a peel-and-seal type of adhesive.

The first pocket and the first flap 44 define the return envelope. The second pocket 40 and the second flap 48 define the outgoing envelope. That is, a fully assembled mailer includes a return envelope disposed within the outgoing envelope. In use, a sender of the mailer 10 inserts items into the second pocket 40. The outgoing envelope is sealed by closing the second flap 48 over the open end 40 a of the second pocket 40. A recipient of the outgoing envelope opens the second flap 48 to remove contents of the second pocket 40. The recipient tears the frangible portions 32, 34 along the line of perforations 36, 38. Then, the first panel 18 is unfolded about the first fold line 16 to reveal the return envelope. The first panel 18 is separated from the second panel 20, or return envelope, along the first fold line 16. Preferably, a plurality of perforations are defined along the first fold line 16 to facilitate the separation of the first 18 and second 20 panels, i.e. a separation of the return and outgoing envelopes.

The blank has two printable sides, on which text and graphics can be applied. FIGS. 1A and 2A illustrate one side of the blank, on which designated areas for a return address 50 and for placement of a postage stamp 52 are preprinted. FIGS. 1B and 2B illustrate the other side of the blank, on which maskings 54 are preprinted to prevent light from readily passing through the mailer that could make the sealed contents visible from outside the outgoing and return envelopes. Optionally, messages or instructions may be preprinted on the panels for the recipient of the mailer. Optionally, the first panel 18 may be provided as a reply document from the sender of the outgoing mailer to include preprinted coupons, questionnaires and the like. Then, upon separation from the second panel 20, the first panel 18 as the reply document can be inserted into the first pocket and sent in the return envelope to the sender.

In FIGS. 3 and 4, an alternative embodiment of the mailer is shown, wherein parts similar to the first embodiment in FIGS. 1 and 2 are indicated by numerals offset by 100. The outgoing envelope portion of the mailer 110 is shown in FIG. 3A, while the return envelope portion of the mailer 110 is shown in FIG. 3B. The alternative embodiment differs from the first embodiment by including a generally clear window 60 in at least one of the panels, preferably the first panel 118, through which a user may have visual access to the contents therein. In FIG. 4A an inside surface of the mailer 110 of FIG. 3A is shown with the panels 118, 120, 124 folded out. Adjacent the second flap 148 is the first panel 118 having the view window 60 as described above for viewing the contents of the second pocket 40 or outgoing envelope. In use, the mailer 110 of the alternative embodiment is the same as described in the first embodiment of FIGS. 1 and 2, except now the window 60 is provided to allow contents of the outgoing envelope to be viewed through the first panel 118. For example, inserts having variable address information can be inserted into the outgoing envelope, such that the information is viewable through the window 60. It should be appreciated that a similar window can be formed in one of the second 120 or third 124 panels to allow visual access to contents of the first pocket or return envelope.

In another embodiment of the invention, inserts (not shown) such as letters, coupons and the like, are placed upon the blank prior to formation of the mailer 10. Then, the inserts are folded with the blank during formation of the mailer 10 and remain as contents sent with the mailer 10 as an outgoing envelope. Preferably, a fugitive adhesive is used to secure the inserts to the blank and to each other as the blank is folded to form the mailer 10. The fugitive adhesive is formulated to dry and release after the mailer 10 has been formed, so that the inserts are freely removable when the mailer 10 is opened by the recipient.

An apparatus and process for forming the inventive mailers is now described, whereby variable imaging is preprinted on both sides of a blank in the form of a flat web of paper which is thereafter fed into a converting apparatus. The apparatus includes a variable image printer that allows both sides of a blank to be preprinted with variable imaging, which may include several types of information. The information includes a portion that is consistent from mailer to mailer, such as return addresses, billing policies, billing procedures and payment procedures. However, each mailer also includes other information, such as addressee information and billing information specific to the addressee.

This information is provided to the variable image printer in electronic form. The information is downloaded from a digital transmission media such as a phone modern, Internet connection or disk.

As shown in FIG. 5, the apparatus 70 includes a reel stand from which a blank or web 74 of printable material, such as paper, is unwound and delivered to a printing station 76 where two spray heads 78, 80 for variable image printing are positioned. Variable image printing requires that the web 74 move horizontally below the spray heads 78, 80. The content of the printing is sprayed onto the web 74 as it moves under the spray head 78, 80. Because the mailers require variable image printing on both sides of the web, one side of the web is passed horizontally under a first spray head 78 to a pair of vertically disposed rollers 82, 84. The web is turned 90° downwardly over the first roller 82 and then turned an additional 90° over the second roller 84 to reverse the sides of the web 74 and pass a second side of the web 74 under the second spray head 80. Thus, the second spray head 80 is mounted beneath the first spray head 78. In this fashion, both sides of the web 74, i.e. mailer, can be printed with the variable imaging.

The web 74 is then moved over a roller 86 to reverse the direction to a scoring station where the web 74 is scored into blanks. The blanks can remain connected so that the web 74 remains continuous and later are separated conventionally by a roller rotating at a higher speed relative to the web 74. Each blank defines one mailer and is printed on both sides. A window for displaying the address of the addressee may be formed on the blank as desired. Each blank is then fed to a scoring and perfing station 92 where the blank is scored for fold lines and impressed with perforations between panels and along the side edges of the blank as required.

Referring to FIG. 6, an inventive folding mechanism for folding the flaps 30 inwardly from the edges 12, 14 of the blank and over the second panel 20 is generally indicated at 150. Only one side 12 of the blank and one side of the folding mechanism 150 are shown and described herein. It should be appreciated, however, that a symmetrically opposite folding mechanism is positioned on the opposite side of the blank for folding its respective flap. That is, the symmetrically opposite sides of the folding mechanism will engage opposite sides of the blank and fold the respective flaps 30 inwardly over the second panel 20 as the blank passes therethrough. The mechanism 150 includes a first bracket 152 and a second bracket 154. The first bracket 152 includes an upper portion 153 and a lower portion extending generally orthogonally therefrom. The upper portion 153 is fixedly secured to the apparatus by conventional means, such as bolting or welding. The lower portion has a leading edge 156 and flat portion 158. The lower portion defines a bottom surface 160 operative for sliding contact with the edge 12 of the blank as it passes thereunder. The bottom surface 160 transitions or slopes downwardly (in the direction of movement of the blank, as indicated by the arrow) between the leading edge 156 and the flat portion 158.

The second bracket 154 includes an upper portion 162 and a lower portion extending generally orthogonally therefrom. The upper portion 162 of the second bracket 154 is fixedly secured to the apparatus 70 by conventional means, such as bolting or welding. The lower portion of the second bracket 154 includes a leading edge 164 and a trailing flat portion 166. The leading edge 164 includes a lower end 168 adjacent the lower portion of the first bracket 152. The leading edge 164 extends upwardly and obtusely from its lower end 168 relative to the lower portion of the first bracket 152. A bottom edge 170 slopes downwardly between the lower end 168 of the leading edge 164 and the trailing flat portion 166. The trailing flat portion 166 defines a generally flat bottom surface. A top surface 172 twists in a generally helical manner between the leading edge 164 and the trailing flat portion 166.

After the edges 12 of the second panel 20 are scored to define the flaps 30, the blank is transported toward the folding mechanism 150, as indicated by the arrow in FIG. 6. Preferably, at this point, the blank along the unfolded portions of the edges 12, 14 should be flat and if not, will engage the downwardly sloping portion of the bottom surface 160 of the first bracket 152. The flaps 30 are blown by air via a nozzle 155, or optionally pushed mechanically by a pin or the like, inwardly so that they are presented for contact with the leading edge 164 and the top surface 172 of the second bracket 154 as the blank is moved in the direction of the arrow. The leading edge 164 and top surface 172, being angled obtusely relative to the lower portion of the first bracket 152, tend to push the flaps 30 increasingly inwardly. Eventually, the flaps 30 engage the bottom edge 170 and bottom surface of the trailing flat portion 166 so that a more definite crease 174 is defined. Optionally, a spring biased roller mechanism or metal finger 180 is operatively coupled to the trailing flat portion 166 to press the flaps 30 against the second panel 20, thereby further defining the crease 174.

The blank is then passed to a station 94 where adhesive is placed on a portion of the sides for forming an envelope pocket. Gumming for a peel-and-seal strip for the return envelope is also applied. The blank then goes to a bottom pocket prefold station and then peel-and-seal release paper 96 is fed from a reel 98 and applied over the peel-and-seal adhesive. The blank then goes to a final folding and gumming station where the final folding and gumming on the flap of the final fold is applied.

From the foregoing there is disclosed an inventive two-way mailer and system for producing the same wherein the mailer provides an outgoing and return envelope. Although the present invention has been described in considerable detail with reference to certain preferred versions or embodiments thereof, other versions may become apparent to those skilled in the art without exceeding the scope of the invention. 

1. A two-way mailer comprising: a blank having: opposite and spaced apart edges; a first fold line extending transversely between the edges of the blank defining adjacent first and second panels, a second fold line extending transversely between the edges of the blank defining a third panel adjacent the second panel, each panel having ends corresponding to the edges of the blank; inwardly foldable flaps formed along the ends of the second panel, the third panel being folded about the second fold line and adhesively secured to the inwardly folded flaps so as to define a first pocket having an open end; and frangible portions formed along the ends of each first and third panel and adhesively secured to each other to define a second pocket having an open end.
 2. A two-way mailer as set forth in claim 1, wherein the blank includes a third fold line formed in the second panel to define a flap that can be folded over the open end of the first pocket.
 3. A two-way mailer as set forth in claim 2 including an adhesive securing the flap to one of the second and third panels for sealing the open end of the first pocket.
 4. A two-way mailer as set forth in claim 1, wherein each end of the second panel includes a pair of transverse cuts that facilitate folding of the inwardly folding flaps over the second panel, one of the transverse cuts being aligned with the second fold line, and the other of the transverse cuts being spaced apart from the third fold line.
 5. A two-way mailer as set forth in claim 1, wherein the blank includes a line of perforations formed along the ends of each first and third panel to facilitate a separation of the frangible portions therefrom.
 6. A two-way mailer as set forth in claim 5, wherein the first pocket is substantially enclosed in the second pocket and is revealed upon separation of the frangible portions from the first and third panels.
 7. A two-way mailer as set forth in claim 1, wherein a fourth fold line is formed in the first panel to define a second flap that can be folded over the open end of the second pocket.
 8. A two-way mailer as set forth in claim 7 including an adhesive securing the second flap to one of the second and third panels for sealing the open end of the second pocket.
 9. A two-way mailer as set forth in claim 1 including a plurality of perforations formed along the first fold line to facilitate a separation of the first and second panels.
 10. A two-way mailer as set forth in claim 1, wherein the blank includes opposite sides each having variable imaging preprinted thereon.
 11. A two-way mailer as set forth in claim 1, wherein one of the panels includes a window that allows viewing of contents contained in the first pocket.
 12. A device for manufacturing two-way mailers from a web having opposite printable sides, the device comprising: a reel stand for supporting the web and from which the web of paper is unwound; a print station having at least two spray heads, the spray heads being spaced apart; a plurality of rollers supporting one portion of the web in a generally horizontal manner so that one of the printable sides is presented to one of the spray heads for printing thereon, the plurality of rollers supporting another portion of the web in a generally horizontal manner so that the other of the printable sides is presented to the other of the spray heads.
 13. A device as set forth in claim 12, wherein the spray heads are vertically spaced apart.
 14. A device as set forth in claim 13, wherein at least one of the plurality of rollers guides the web generally orthogonally along a generally vertical path after one of the printable sides has been printed by one of the spray heads.
 15. A device as set forth in claim 14, wherein at least another of the plurality of rollers guides the web generally orthogonally from the vertical path toward the other of the spray heads so that the other of the printable sides can be printed.
 16. A device as set forth in claim 12 including a scoring mechanism that scores tranversely extending fold lines along the web defining a plurality of separable blanks therealong, wherein each blank has at least three panels foldable about the fold lines to define at least one pocket, and wherein each panel extends transversely between opposite ends.
 17. A device as set forth in claim 16, wherein the scoring mechanism scores longitudinal fold lines along each end of each panel.
 18. A device as set forth in claim 17 including a cutting mechanism for forming spaced apart transversely extending cuts at the ends of at least one panel of each blank, the cuts defining inwardly foldable flaps at the ends of the at least one panel of each blank.
 19. A device as set forth in claim 18 including a folding mechanism for folding the flaps inwardly toward each other, the folding mechanism including a bracket having a bottom edge that engages the foldable flaps as the blank is fed to the folding mechanism, the bottom edge sloping downwardly toward a trailing flat portion that presses and folds the foldable flaps in a position overlying the blank.
 20. A device as set forth in claim 19, wherein the bracket includes a leading edge extending upwardly and obtusely from the bottom edge engaging the foldable flap and displacing the flap inwardly toward the position overlying the blank.
 21. A device as set forth in claim 20, wherein the bracket includes a top surface twisted in a helical manner between the leading edge and the trailing flat portion.
 22. A device as set forth in claim 20 including a mechanism for displacing the foldable flaps inwardly as the web is fed to the folding mechanism to ensure proper engagement between the foldable flaps and the leading edge of the bracket.
 23. A method of forming an envelope having an insert disposed therein, the method comprising the steps of: providing a blank having a plurality of panels; placing the insert onto the blank prior to folding of the plurality of panels; and folding the panels in an overlying manner so as to define a pocket with the inserts supported therein.
 24. A method as set forth in claim 23 including the step of applying an adhesive to form a bond between the insert and the blank securing the insert to the blank during formation of the pocket.
 25. A method as set forth in claim 23 including the step of applying a fugitive adhesive to form a releasable bond between the insert and the blank securing the insert to the blank during formation of the pocket, whereafter the fugitive adhesive dries and releases the bond between the insert and the blank so that the insert is freely removable from the pocket by a recipient of the envelope. 